Method of assembling a modular multi-panel display system

ABSTRACT

Embodiments of the present invention relate to integrated modular display systems. In one embodiment, a modular multi-panel display system includes a mechanical support structure, and a plurality of display panels detachably mounted to the mechanical support structure so as to form an integrated display panel. Each LED panel includes an LED array and an LED driver coupled to the LED array. Each panel further includes a power supply unit disposed outside the housing and electrically coupled to the receiver circuit. The mechanical structure is configured to provide mechanical support to the plurality of display panels without providing hermetic sealing. Each of the plurality of display panels is hermetically sealed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 15/396,102filed on Dec. 30, 2016, (U.S. Pat. No. 9,642,272), which is acontinuation of application Ser. No. 14/948,939 (U.S. Pat. No.9,535,650) filed on Nov. 23, 2015, which is a continuation ofapplication Ser. No. 14/341,678 filed on Jul. 25, 2014 (U.S. Pat. No.9,195,281), which claims the benefit of U.S. Provisional Application No.62/025,463, filed on Jul. 16, 2014 and also the benefit of U.S.Provisional Application No. 61/922,631, filed on Dec. 31, 2013, whichapplications are hereby incorporated herein by reference.

U.S. patent application Ser. No. 14/328,624, filed Jul. 10, 2014, alsoclaims priority to U.S. Provisional Application No. 61/922,631 and isalso incorporated herein by reference. The following applications arealso related to this provisional application: U.S. patent applicationSer. Nos. 14/444,719; 14/444,747; 14/444,775; 14/550,685; 14/582,908;14/627,923; 14/641,130; 14/641,189; 14/664,526; 14/720,544; 14/720,560;14/720,610; 14/829,469; 14/850,632; U.S. Patent Application No.62/065,510; U.S. Patent Application No. 62/093,157; U.S. PatentApplication No. 62/113,342; U.S. Patent Application No. 62/158,707; U.S.Patent Application No. 62/158,989; and PCT Patent Application No.PCT/US14/72373.

TECHNICAL FIELD

The present invention relates generally to displays, and, in particularembodiments, to a system and method for a modular multi-panel display.

BACKGROUND

Large displays (e.g., billboards), such as those commonly used foradvertising in cities and along roads, generally have one or morepictures and/or text that are to be displayed under various light andweather conditions. As technology has advanced and introduced newlighting devices such as the light emitting diode (LED), such advanceshave been applied to large displays. An LED display is a flat paneldisplay, which uses an array of light-emitting diodes. A large displaymay be made of a single LED display or a panel of smaller LED panels.LED panels may be conventional panels made using discrete LEDs orsurface-mounted device (SMD) panels. Most outdoor screens and someindoor screens are built around discrete LEDs, which are also known asindividually mounted LEDs. A cluster of red, green, and blue diodes isdriven together to form a full-color pixel, usually square in shape.These pixels are spaced evenly apart and are measured from center tocenter for absolute pixel resolution.

SUMMARY

Embodiments of the invention relate to lighting systems and, moreparticularly, to multi-panel lighting systems for providing interior orexterior displays.

In one embodiment, a modular multi-panel display system comprises amechanical support structure. A plurality of LED display panels isdetachably mounted to the mechanical support structure so as to form anintegrated display panel. Each LED panel includes an LED array and areceiver circuit disposed within a housing. The receiver circuitincludes an LED driver coupled to the LED array. Each panel furtherincludes a power supply unit disposed outside the housing andelectrically coupled to the receiver circuit. The mechanical structureis configured to provide mechanical support to the plurality of LEDdisplay panels without providing hermetic sealing. Each of the pluralityof LED display panels is hermetically sealed.

In one embodiment, a modular multi-panel display system comprises anouter frame including a top beam, a bottom beam, a left outside beam,and a right outside beam. A plurality of vertical beams extends from thetop beam to the bottom beam within the outer frame. Each of the verticalbeams has a smaller diameter and weighs less than any beam of the outerframe. An array of LED display panels is arranged in rows and columns.Each LED display panel is attached to at least one of the verticalbeams. The array forms an integrated display panel. The display systemincludes no cabinets, and is cooled passively and includes no airconditioning, fans, or heating units.

In another embodiment, a method of assembling a modular multi-paneldisplay system comprises assembling a mechanical support structure thatincludes an outer frame including a top beam, a bottom beam, a leftoutside beam, and a right outside beam. A plurality of vertical beamsextends from the top beam to the bottom beam within the outer frame.Each of the vertical beams has a smaller diameter and weighs less thanany beam of the outer frame. A plurality of LED display panels ismounted to the mechanical support structure so as to form an integrateddisplay panel that includes an array of rows and columns of LED displaypanels. Each of the LED display panels is hermetically sealed. Each ofthe LED display panels is electrically connected to a data source and toa power source. The assembled multi-panel display system includes nocabinets, and is cooled passively and includes no air conditioning orfans.

In yet another embodiment, a method of maintaining a modular multi-paneldisplay that includes a mechanical support structure and a plurality ofLED display panels detachably coupled to the mechanical supportstructure without a cabinet. Each LED display panel is mechanicallycoupled to the mechanical support structure and three other lightingpanels by a corner plate. The method further includes determining that adefective LED display panel has a defect and electrically disconnectingthe defective LED display panel from the multi-panel display. The cornerplate is removed from the defective LED display panel. The defective LEDdisplay panel is removed from the multi-panel display. A replacement LEDdisplay panel is placed at a location formerly taken by the defectiveLED display panel. The corner plate is attached to the replacement LEDdisplay panel. The replacement LED display panel is electricallyconnected to the multi-panel display.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding, reference is now made to thefollowing description taken in conjunction with the accompanyingdrawings in which:

FIGS. 1A and 1B illustrate one embodiment of a display that may beprovided according to the present disclosure;

FIGS. 2A-2C illustrate one embodiment of a lighting panel that may beused with the display of FIGS. 1A and 1B;

FIGS. 3A-3I illustrate one embodiment of a housing and an alignmentplate that may be used with the panel of FIG. 2A;

FIGS. 4A and 4B illustrate a more detailed embodiment of the panel ofFIG. 2A;

FIG. 5 illustrates an alternative embodiment of the panel of FIG. 4A;

FIGS. 6A and 6B illustrate a more detailed embodiment of the panel ofFIG. 2A;

FIG. 7 illustrates an alternative embodiment of the panel of FIG. 6A;

FIGS. 8A-8M illustrate one embodiment of a frame that may be used withthe display of FIGS. 1A and 1B;

FIGS. 9A-9C illustrate one embodiment of a locking mechanism that may beused with the display of FIGS. 1A and 1B;

FIGS. 10A-10D illustrate one embodiment of a display configuration;

FIGS. 11A-11D illustrate another embodiment of a display configuration;

FIGS. 12A-12D illustrate yet another embodiment of a displayconfiguration;

FIG. 13 illustrates a modular display panel in accordance with anembodiment of the present invention;

FIG. 14 illustrates a modular display panel attached to a supportingframe in accordance with an embodiment of the present invention;

FIG. 15 illustrates a frame used to provide mechanical support to themodular display panel in accordance with an embodiment of the presentinvention;

FIGS. 16A-16E illustrate an attachment plate used to attach one or moremodular display panels to the frame in accordance with an embodiment ofthe present invention, wherein FIG. 16A illustrates a projection viewwhile FIG. 16B illustrates a top view and FIG. 16C illustrates across-sectional view of a first embodiment while FIG. 16D illustrates abottom view and FIG. 16 E illustrates a bottom view of a secondembodiment;

FIG. 17 illustrates a magnified view of the attachment plate or aconnecting plate, frame, and display panel after mounting in accordancewith embodiments of the present invention;

FIG. 18 illustrates one unit of the modular display panel in accordancewith an embodiment of the present invention;

FIG. 19 illustrates a magnified view of two display panels next to eachother and connected through the cables such that the output cable of theleft display panel is connected with the input cable of the next displaypanel in accordance with an embodiment of the present invention;

FIG. 20 illustrates a modular multi-panel display system comprising aplurality of LED display panels connected together using theafore-mentioned cables in accordance with an embodiment of the presentinvention;

FIGS. 21A-21C illustrate an alternative embodiment of the modulardisplay panel attached to a supporting frame in accordance with anembodiment of the present invention, wherein FIGS. 21B and 21Cillustrate alternative structural embodiments of the supporting frame;

FIG. 22 illustrates a method of assembling a modular multi-panel displaysystem in accordance with an embodiment of the present invention;

FIG. 23 illustrates an assembled multi-panel display that is ready forshipment;

FIG. 24 illustrates a method of maintaining a modular multi-paneldisplay that includes a mechanical support structure and a plurality ofLED display panels detachably coupled to the mechanical supportstructure without a cabinet in accordance with an embodiment of thepresent invention;

FIGS. 25A-25D illustrate specific examples of an assembled displaysystem; and

FIG. 26 illustrates a specific example of a frame that can be used withthe system of FIGS. 25A-25D.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In the following discussion, exterior displays are used herein forpurposes of example. It is understood that the present disclosure may beapplied to lighting for any type of interior and/or exterior display.

Embodiments of the invention provide display panels, each of whichprovides a completely self-contained building block that is lightweight.These displays are designed to protect against weather, without a heavycabinet. The panel can be constructed of aluminum or plastic so that itwill about 50% lighter than typical panels that are commerciallyavailable. The lightweight design allows for easier installation andmaintenance, thus lowering total cost of ownership.

In certain embodiments, the display is IP 67 rated and thereforewaterproof and corrosion resistant. Because weather is the number oneculprit for damage to LED displays, an IP 67 rating providesweatherproofing with significant weather protection. These panels arecompletely waterproof against submersion in up to 3 feet of water. Inother embodiments, the equipment can be designed with an IP 68 rating tooperate completely underwater. In lower-cost embodiments whereweatherproofing is not as significant, the panels can have an IP 65 orIP 66 rating.

One aspect takes advantage of a no cabinet design-new technology thatreplaces cabinets, which are necessary in commercial embodiments. Oldertechnology incorporates the use of cabinets in order to protect the LEDdisplay electronics from rain. This creates an innate problem in thatthe cabinet must not allow rain to get inside to the electronics, whileat the same time the cabinet must allow for heat created by theelectronics and ambient heat to escape.

Embodiments that do not use this cabinet technology avoid a multitude ofproblems inherent to cabinet-designed displays. One of the problems thathas been solved is the need to effectively cool the LED display. MostLED manufacturers must use air-conditioning (HVAC) to keep theirdisplays cool. This technology greatly increases the cost ofinstallation and performance.

Displays of the present invention can be designed to be light weight andeasy to handle. For example, the average total weight of a 20 mm,14′×48′ panel can be 5,500 pounds or less while typical commerciallyavailable panels are at 10,000 to 12,000 pounds. These units are moremaneuverable and easier to install saving time and money in the process.

Embodiments of the invention provide building block panels that areconfigurable with future expandability. These displays can offercomplete expandability to upgrade in the future without having toreplace the entire display. Installation is fast and easy with verylittle down-time, which allows any electronic message to be presentedmore quickly.

In some embodiments, the display panels are “hot swappable.” By removingone screw in each of the four corners of the panel, servicing thedisplay is fast and easy. Since a highly-trained, highly-paidelectrician or LED technician is not needed to correct a problem, costbenefits can be achieved.

Various embodiments utilize enhanced pixel technology (EPT), whichincreases image capability. EPT allows image displays in the physicalpitch spacing, but also has the ability to display the image in aresolution that is four-times greater. Images will be as sharp and crispwhen viewed close as when viewed from a distance, and at angles.

In some embodiments it is advantageous to build multipanel displayswhere each of the LEDs is provided by a single LED manufacturer, so thatdiodes of different origin in the manufacture are not mixed. It has beendiscovered that diode consistency can aid in the quality of the visualimage. While this feature is not necessary, it is helpful becausedisplays made from different diodes from different suppliers can createpatchy inconsistent color, e.g., “pink” reds and pink looking casts tothe overall image.

Referring to FIGS. 1A and 1B, one embodiment of a multi-panel display100 is illustrated. The display 100 includes a display surface 102 thatis formed by multiple lighting panels 104 a-104 t. In the presentembodiment, the panels 104 a-104 t use light emitting diodes (LEDs) forillumination, but it is understood that other light sources may be usedin other embodiments. The panels 104 a-104 t typically operate togetherto form a single image, although multiple images may be simultaneouslypresented by the display 100. In the present example, the panels 104a-104 t are individually attached to a frame 106, which enables eachpanel to be installed or removed from the frame 106 without affectingthe other panels.

Each panel 104 a-104 t is a self-contained unit that couples directly tothe frame 106. By “directly,” it is understood that another component orcomponents may be positioned between the panel 104 a-104 t and the frame106, but the panel is not placed inside a cabinet that is coupled to theframe 106. For example, an alignment plate (described later but notshown in the present figure) may be coupled to a panel and/or the frame106 to aid in aligning a panel with other panels. Further a corner platecould be used. The panel may then be coupled to the frame 106 or thealignment plate and/or corner plate, and either coupling approach wouldbe “direct” according to the present disclosure.

Two or more panels 104 a-104 t can be coupled for power and/or datapurposes, with a panel 104 a-104 t receiving power and/or data from acentral source or another panel and passing through at least some of thepower and/or data to one or more other panels. This further improves themodular aspect of the display 100, as a single panel 104 a-104 t can beeasily connected to the display 100 when being installed and easilydisconnected when being removed by decoupling the power and dataconnections from neighboring panels.

The power and data connections for the panels 104 a-104 t may beconfigured using one or more layouts, such as a ring, mesh, star, bus,tree, line, or fully-connected layout, or a combination thereof. In someembodiments the LED panels 104 a-104 t may be in a single network, whilein other embodiments the LED panels 104 a-104 t may be divided intomultiple networks. Power and data may be distributed using identical ordifferent layouts. For example, power may be distributed in a linelayout, while data may use a combination of line and star layouts.

The frame 106 may be relatively light in weight compared to framesneeded to support cabinet mounted LED assemblies. In the presentexample, the frame 106 includes only a top horizontal member 108, abottom horizontal member 110, a left vertical member 112, a rightvertical member 114, and intermediate vertical members 116. Power cablesand data cables (not shown) for the panels 104 a-104 t may route aroundand/or through the frame 106.

In one example, the display 100 includes 336 panels 104 a-104 t, e.g.,to create a 14′×48′ display. As will be discussed below, because eachpanel is lighter than typical panels, the entire display could be builtto weigh only 5500 pounds. This compares favorably to commerciallyavailable displays of the size, which generally weigh from 10,000 to12,000 pounds.

Referring to FIGS. 2A-2C, one embodiment of an LED panel 200 isillustrated that may be used as one of the LED panels 104 a-104 t ofFIGS. 1A and 1B. FIG. 2A illustrates a front view of the panel 200 withLEDs aligned in a 16×32 configuration. FIG. 2B illustrates a diagram ofinternal components within the panel 200. FIG. 2C illustrates onepossible configuration of a power supply positioned within the panel 200relative to a back plate of the panel 200.

Referring specifically to FIG. 2A, in the present example, the LED panel200 includes a substrate 202 that forms a front surface of the panel200. The substrate 202 in the present embodiment is rectangular inshape, with a top edge 204, a bottom edge 206, a right edge 208, and aleft edge 210. A substrate surface 212 includes “pixels” 214 that areformed by one or more LEDs 216 on or within the substrate 202. In thepresent example, each pixel 214 includes four LEDs 216 arranged in apattern (e.g., a square). For example, the four LEDs 216 that form apixel 214 may include a red LED, a green LED, a blue LED, and one otherLED (e.g., a white LED). In some embodiments, the other LED may be asensor. It is understood that more or fewer LEDs 216 may be used to forma single pixel 214, and the use of four LEDs 216 and their relativepositioning as a square is for purposes of illustration only.

In some embodiments, the substrate 202 may form the entire front surfaceof the panel 200, with no other part of the panel 200 being visible fromthe front when the substrate 202 is in place. In other embodiments, ahousing 220 (FIG. 2B) may be partially visible at one or more of theedges of the substrate 202. The substrate 202 may form the front surfaceof the panel 202, but may not be the outer surface in some embodiments.For example, a transparent or translucent material or coating mayoverlay the substrate 202 and the LEDs 216, thereby being positionedbetween the substrate 202/LEDs 216 and the environment.

As one example, a potting material can be formed over the LEDs 216. Thismaterial can be applied as a liquid, e.g., while heated, and then hardenover the surface, e.g., when cooled. This potting material is useful forenvironmental protection, e.g., to achieve an IP rating of IP 65 orhigher.

Louvers 218 may be positioned above each row of pixels 214 to block orminimize light from directly striking the LEDs 216 from certain angles.For example, the louvers 218 may be configured to extend from thesubstrate 202 to a particular distance and/or at a particular angleneeded to completely shade each pixel 214 when a light source (e.g., thesun) is at a certain position (e.g., ten degrees off vertical). In thepresent example, the louvers 208 extend the entire length of thesubstrate 202, but it is understood that other louver configurations maybe used.

Referring specifically to FIG. 2B, one embodiment of the panel 200illustrates a housing 220. The housing 220 contains circuitry 222 and apower supply 224. The circuitry 222 is coupled to the LEDs 216 and isused to control the LEDs. The power supply 224 provides power to theLEDs 216 and circuitry 222. As will be described later in greater detailwith respect to two embodiments of the panel 200, data and/or power maybe received for only the panel 200 or may be passed on to one or moreother panels as well. Accordingly, the circuitry 222 and/or power supply224 may be configured to pass data and/or power to other panels in someembodiments.

In the present example, the housing 220 is sealed to prevent water fromentering the housing. For example, the housing 220 may be sealed to havean ingress protection (IP) rating such as IP 67, which defines a levelof protection against both solid particles and liquid. This ensures thatthe panel 200 can be mounted in inclement weather situations withoutbeing adversely affected. In such embodiments, the cooling is passive asthere are no vent openings for air intakes or exhausts. In otherembodiments, the housing may be sealed to have an IP rating of IP 65 orhigher, e.g. IP 65, IP 66, IP 67, or IP 68.

Referring specifically to FIG. 2C, one embodiment of the panel 200illustrates how the power supply 224 may be thermally coupled to thehousing 220 via a thermally conductive material 226 (e.g., aluminum).This configuration may be particularly relevant in embodiments where thepanel 200 is sealed and cooling is passive.

Referring to FIGS. 3A-3I, one embodiment of a housing 300 is illustratedthat may be used with one of the LED panels 104 a-104 t of FIGS. 1A and1B. For example, the housing 300 may be a more specific example of thehousing 220 of FIG. 2B. In FIGS. 3B-3I, the housing 300 is shown with analignment plate, which may be separate from the housing 300 or formed aspart of the housing 300. In the present example, the housing 300 may bemade of a thermally conductive material (e.g., aluminum) that isrelatively light weight and rigid. In other embodiments, the housing 300could be made out of industrial plastic, which is even lighter thanaluminum.

As shown in the orthogonal view of FIG. 3A, the housing 300 defines acavity 302. Structural cross-members 304 and 306 may be used to providesupport to a substrate (e.g., the substrate 202 of FIG. 2A) (not shown).The cross-members 304 and 306, as well as other areas of the housing300, may include supports 308 against which the substrate can rest whenplaced into position. As shown, the supports 308 may include arelatively narrow tip section that can be inserted into a receiving holein the back of the substrate and then a wider section against which thesubstrate can rest.

The housing 300 may also include multiple extensions 310 (e.g., sleeves)that provide screw holes or locations for captive screws that can beused to couple the substrate to the housing 300. Other extensions 312may be configured to receive pins or other protrusions from a lockingplate and/or fasteners, which will be described later in greater detail.Some or all of the extensions 312 may be accessible only from the rearside of the housing 300 and so are not shown as openings in FIG. 3A.

As shown in FIG. 3B, an alignment plate 314 may be used with the housing300. The alignment plate is optional. The alignment plate 314, whenused, aids in aligning multiple panels on the frame 106 to ensure thatthe resulting display surface has correctly aligned pixels bothhorizontally and vertically. To accomplish this, the alignment plate 314includes tabs 316 and slots 318 (FIG. 3F). Each tab 316 fits into theslot 318 of an adjoining alignment plate (if present) and each slot 318receives a tab from an adjoining alignment plate (if present). Thisprovides an interlocking series of alignment plates. As each alignmentplate 314 is coupled to or part of a housing 300, this results incorrectly aligning the panels on the frame 106.

It is understood that, in some embodiments, the alignment plate 314 maybe formed as part of the panel or the alignment functionality providedby the alignment plate 314 may be achieved in other ways. In still otherembodiments, a single alignment panel 314 may be formed to receivemultiple panels, rather than a single panel as shown in FIG. 3B.

In other embodiments, the alignment functionality is eliminated. Thedesign choice of whether to use alignment mechanisms (e.g., slots andgrooves) is based upon a tradeoff between the additional alignmentcapability and the ease of assembly.

As shown in FIG. 3C, the housing 300 may include beveled or otherwisenon-squared edges 320. This shaping of the edges enables panels to bepositioned in a curved display without having large gaps appear as wouldoccur if the edges were squared.

Referring to FIGS. 4A and 4B, one embodiment of a panel 400 isillustrated that may be similar or identical to one of the LED panels104 a-104 t of FIGS. 1A and 1B. The panel 400 may be based on a housing401 that is similar or identical to the housing 300 of FIG. 3A. FIG. 4Aillustrates a back view of the panel 400 and FIG. 4B illustrates a topview. The panel 400 has a width W and a height H.

In the present example, the back includes a number of connection pointsthat include a “power in” point 402, a “data in” point 404, a main “dataout” point 406, multiple slave data points 408, and a “power out” point410. As will be discussed below, one embodiment of the inventionprovides for an integrated data and power cable, which reduces thenumber of ports. The power in point 402 enables the panel 400 to receivepower from a power source, which may be another panel. The data in point404 enables the panel to receive data from a data source, which may beanother panel. The main data out point 406 enables the panel 400 to senddata to another main panel. The multiple slave data points 408, whichare bi-directional in this example, enable the panel 400 to send data toone or more slave panels and to receive data from those slave panels. Insome embodiments, the main data out point 406 and the slave data outpoints 408 may be combined. The power out point 410 enables the panel400 to send power to another panel.

The connection points may be provided in various ways. For example, inone embodiment, the connection points may be jacks configured to receivecorresponding plugs. In another embodiment, a cable may extend from theback panel with a connector (e.g., a jack or plug) affixed to theexternal end of the cable to provide an interface for another connector.It is understood that the connection points may be positioned andorganized in many different ways.

Inside the panel, the power in point 402 and power out point 410 may becoupled to circuitry (not shown) as well as to a power supply. Forexample, the power in point 402 and power out point 410 may be coupledto the circuitry 222 of FIG. 2B, as well as to the power supply 224. Insuch embodiments, the circuitry 222 may aid in regulating the receptionand transmission of power. In other embodiments, the power in point 402and power out point 410 may by coupled only to the power supply 224 witha pass through power connection allowing some of the received power tobe passed from the power in point 402 to the power out point 410.

The data in point 404, main data out point 406, and slave data outpoints 408 may be coupled to the circuitry 222. The circuitry 222 mayaid in regulating the reception and transmission of the data. In someembodiments, the circuitry 222 may identify data used for the panel 400and also send all data on to other coupled main and slave panels via themain data out point 406 and slave data out points 408, respectively. Insuch embodiments, the other main and slave panels would then identifythe information relevant to that particular panel from the data. Inother embodiments, the circuitry 222 may remove the data needed for thepanel 400 and selectively send data on to other coupled main and slavepanels via the main data out point 406 and slave data out points 408,respectively. For example, the circuitry 222 may send only datacorresponding to a particular slave panel to that slave panel ratherthan sending all data and letting the slave panel identify thecorresponding data.

The back panel also has coupling points 412 and 414. In the examplewhere the housing is supplied by the housing 300 of FIG. 3A, thecoupling points 412 and 414 may correspond to extensions 310 and 312,respectively.

Referring specifically to FIG. 4B, a top view of the panel 400illustrates three sections of the housing 401. The first section 416includes the LEDs (not shown) and louvers 418. The second section 420and third section 422 may be used to house the circuitry 222 and powersupply 224. In the present example, the third section 422 is an extendedsection that may exist on main panels, but not slave panels, due toextra components needed by a main panel to distribute data. Depths D1,D2, and D3 correspond to sections 416, 420, and 422, respectively.

Referring to FIG. 5, one embodiment of a panel 500 is illustrated thatmay be similar or identical to the panel 400 of FIG. 4A with theexception of a change in the slave data points 408. In the embodiment ofFIG. 4A, the slave data points 408 are bi-directional connection points.In the present embodiment, separate slave “data in” points 502 and slave“data out” points 504 are provided. In other embodiments, the datapoints can be directional connection points.

Referring to FIGS. 6A and 6B, one embodiment of a panel 600 isillustrated that may be similar or identical to the panel 400 of FIG. 4Aexcept that the panel 600 is a slave panel. FIG. 6A illustrates a backview of the panel 600 and FIG. 6B illustrates a top view. The panel 400has a width W and a height H. In the present embodiment, these areidentical to the width W and height H of the panel 400 of FIG. 4A. Inone example, the width W can be between 1 and 4 feet and the height Hcan be between 0.5 and 4 feet, for example 1 foot by 2 feet. Of course,the invention is not limited to these specific dimensions.

In contrast to the main panel of FIG. 4A, the back of the slave panel600 has a more limited number of connection points that include a “powerin” point 602, a data point 604, and a “power out” point 606. The powerin point 602 enables the panel 600 to receive power from a power source,which may be another panel. The data point 604 enables the panel toreceive data from a data source, which may be another panel. The powerout point 606 enables the panel 600 to send power to another main panel.In the present example, the data point 604 is bi-directional, whichcorresponds to the main panel configuration illustrated in FIG. 4A. Theback panel also has coupling points 608 and 610, which correspond tocoupling points 412 and 414, respectively, of FIG. 4A. As discussedabove, other embodiments use directional data connections.

Referring specifically to FIG. 6B, a top view of the panel 600illustrates two sections of the housing 601. The first section 612includes the LEDs (not shown) and louvers 614. The second section 616may be used to house the circuitry 222 and power supply 224. In thepresent example, the extended section provided by the third section 422of FIG. 4A is not needed as the panel 600 does not pass data on to otherpanels. Depths D1 and D2 correspond to sections 612 and 616,respectively. In the present embodiment, depths D1 and D2 are identicalto depths D1 and D2 of the panel 400 of FIG. 4B. In one example, thedepth D1 can be between 1 and 4 inches and the depths D2 can be between1 and 4 inches.

It is noted that the similarity in size of the panels 400 of FIG. 4A andthe panel 600 of FIG. 6A enables the panels to be interchanged asneeded. More specifically, as main panels and slave panels have anidentical footprint in terms of height H, width W, and depth D1, theirposition on the frame 106 of FIGS. 1A and 1B does not matter from a sizestandpoint, but only from a functionality standpoint. Accordingly, thedisplay 100 can be designed as desired using main panels and slavepanels without the need to be concerned with how a particular panel willphysically fit into a position on the frame. The design may then focuson issues such as the required functionality (e.g., whether a main panelis needed or a slave panel is sufficient) for a particular positionand/or other issues such as weight and cost.

In some embodiments, the main panel 400 of FIG. 4A may weigh more thanthe slave panel 600 due to the additional components present in the mainpanel 400. The additional components may also make the main panel 400more expensive to produce than the slave panel 600. Therefore, a displaythat uses as many slave panels as possible while still meeting requiredcriteria will generally cost less and weigh less than a display thatuses more main panels.

Referring to FIG. 7, one embodiment of a panel 700 is illustrated thatmay be similar or identical to the panel 600 of FIG. 6A with theexception of a change in the data point 604. In the embodiment of FIG.6A, the data point 604 is a bi-directional connection. In the presentembodiment, a separate “data out” point 702 and a “data in” point 704are provided, which corresponds to the main panel configurationillustrated in FIG. 5.

Referring to FIGS. 8A-8M, embodiments of a frame 800 are illustrated.For example, the frame 800 may provide a more detailed embodiment of theframe 106 of FIG. 1B. As described previously, LED panels, such as thepanels 104 a-104 t of FIGS. 1A and 1B, may be mounted directly to theframe 800. Accordingly, the frame 800 does not need to be designed tosupport heavy cabinets, but need only be able to support the panels 104a-104 t and associated cabling (e.g., power and data cables), and theframe 800 may be lighter than conventional frames that have to supportcabinet based structures. For purposes of example, various referencesmay be made to the panel 200 of FIG. 2A, the housing 300 of FIG. 3A, andthe panel 400 of FIG. 4A.

In the present example, the frame 800 is designed to support LED panels802 in a configuration that is ten panels high and thirty-two panelswide. While the size of the panels 802 may vary, in the currentembodiment this provides a display surface that is approximately fiftyfeet and four inches wide (50′ 4″) and fifteen feet and eight andthree-quarters inches high (15′ 8.75″).

It is understood that all measurements and materials described withrespect to FIGS. 8A-8M are for purposes of example only and are notintended to be limiting. Accordingly, many different lengths, heights,thicknesses, and other dimensional and/or material changes may be madeto the embodiments of FIGS. 8A-8M.

Referring specifically to FIG. 8B, a back view of the frame 800 isillustrated. The frame 800 includes a top bar 804, a bottom bar 806, aleft bar 808, a right bar 810, and multiple vertical bars 812 thatconnect the top bar 804 and bottom bar 806. In some embodiments,additional horizontal bars 814 may be present.

The frame 800 may be constructed of various materials, including metals.For example, the top bar 804, the bottom bar 806, the left bar 808, andthe right bar 810 (e.g., the perimeter bars) may be made using a fourinch aluminum association standard channel capable of bearing 1.738lb/ft. The vertical bars 812 may be made using 2″×4″×½″ aluminum tubecapable of bearing a load of 3.23 lb/ft. it is understood that otherembodiments will utilize other size components.

It is understood that these sizes and load bearing capacities are forpurposes of illustration and are not intended to be limiting. However,conventional steel display frames needed to support conventionalcabinet-based displays are typically much heavier than the frame 800,which would likely not be strong enough to support a traditionalcabinet-based display. For example, the frame 800 combined with thepanels described herein may weigh at least fifty percent less thanequivalent steel cabinet-based displays.

Referring to FIG. 8C, a cutaway view of the frame 800 of FIG. 8B takenalong lines A1-A1 is illustrated. The horizontal bars 810 are moreclearly visible. More detailed views of FIG. 8C are described below.

Referring to FIG. 8D, a more detailed view of the frame 800 of FIG. 8Cat location B1 is illustrated. The cutaway view shows the top bar 804and a vertical bar 812. A first flat bar 816 may be used with multiplefasteners 818 to couple the top bar 804 to the vertical bar 812 at theback of the frame 800. A second flat bar 820 may be used with fasteners821 to couple the top bar 804 to the vertical bar 812 at the front ofthe frame 800. A front plate 902 belonging to a coupling mechanism 900(described below with respect to FIG. 9A) is illustrated. The secondflat bar 820 may replace a back plate of the coupling mechanism 900. Inembodiments where the second flat bar 820 replaces the back plate, thesecond flat bar 820 may include one or more holes to provideaccessibility to fasteners of the coupling mechanism 900.

Referring to FIGS. 8E-8G, various more detailed views of the frame 800of FIG. 8C are illustrated. FIG. 8E provides a more detailed view of theframe 800 of FIG. 8C at location B2. FIG. 8F provides a cutaway view ofthe frame 800 of FIG. 8E taken along lines C1-C1. FIG. 8G provides acutaway view of the frame 800 of FIG. 8E taken along lines C2-C2.

A clip 822 may be coupled to a vertical bar 812 via one or morefasteners 824 and to the horizontal bar 814 via one or more fasteners824. In the present example, the clip 822 is positioned above thehorizontal bar 814, but it is understood that the clip 822 may bepositioned below the horizontal bar 814 in other embodiments. In stillother embodiments, the clip 822 may be placed partially inside thehorizontal bar 814 (e.g., a portion of the clip 822 may be placedthrough a slot or other opening in the horizontal bar 814).

Referring to FIGS. 8H and 8I, various more detailed views of the frame800 of FIG. 8C are illustrated. FIG. 8H provides a more detailed view ofthe frame 800 of FIG. 8C at location B3. FIG. 8I provides a cutaway viewof the frame 800 of FIG. 8H taken along lines D1-D1.

The cutaway view shows the bottom bar 806 and a vertical bar 812. Afirst flat bar 826 may be used with multiple fasteners 828 to couple thebottom bar 806 to the vertical bar 812 at the back of the frame 800. Asecond flat bar 830 may be used with fasteners 832 to couple the bottombar 806 to the vertical bar 812 at the front of the frame 800. A frontplate 902 belonging to a coupling mechanism 900 (described below withrespect to FIG. 9A) is illustrated. The second flat bar 830 may replacea back plate of the coupling mechanism 900. In embodiments where thesecond flat bar 830 replaces the back plate, the second flat bar 830 mayinclude one or more holes to provide accessibility to fasteners of thecoupling mechanism 900.

Referring to FIGS. 8J and 8K, various more detailed views of the frame800 of FIG. 8A are illustrated. FIG. 8H provides a more detailed view ofthe frame 800 of FIG. 8B at location A2. FIG. 8K provides a cutaway viewof the frame 800 of FIG. 8J taken along lines E1-E1. The two views showthe bottom bar 806 and the left bar 808. A clip 834 may be used withmultiple fasteners 836 to couple the bottom bar 806 to the left bar 808at the corner of the frame 800.

Referring to FIGS. 8L and 8M, an alternative embodiment to FIG. 8E isillustrated. FIG. 8L provides a more detailed view of the frame 800 inthe alternate embodiment. FIG. 8M provides a cutaway view of the frame800 of FIG. 8L taken along lines F1-F1. In this embodiment, rather thanusing a horizontal bar 814, a vertical bar 812 is coupled directly to abeam 840 using a clip 838.

Referring to FIGS. 9A-9C, one embodiment of a coupling mechanism 900 isillustrated that may be used to attach an LED panel (e.g., one of thepanels 104 a-104 t of FIGS. 1A and 1B) to a frame (e.g., the frame 106or the frame 800 of FIGS. 8A and 8B). For purposes of example, thecoupling mechanism 900 is described as attaching the panel 200 of FIG.2A to the frame 800 of FIG. 8B. In the present example, a singlecoupling mechanism 900 may attach up to four panels to the frame 800. Toaccomplish this, the coupling mechanism 900 is positioned where thecorners of four panels meet.

The coupling mechanism 900 includes a front plate 902 and a back plate904. The front plate 902 has an outer surface 906 that faces the back ofa panel and an inner surface 908 that faces the frame 106. The frontplate 902 may include a center hole 910 and holes 912. The center hole910 may be countersunk relative to the outer surface 906 to allow a bolthead to sit at or below the outer surface 906. Mounting pins 914 mayextend from the outer surface 906. The back plate 904 has an outersurface 916 that faces away from the frame 106 and an inner surface 918that faces the frame 106. The back plate 904 includes a center hole 920and holes 922.

In operation, the front plate 902 and back plate 904 are mounted onopposite sides of one of the vertical bars 808, 810, or 812 with thefront plate 902 mounted on the panel side of the frame 800 and the backplate 904 mounted on the back side of the frame 800. For purposes ofexample, a vertical bar 812 will be used. When mounted in this manner,the inner surface 908 of the front plate 902 and the inner surface 918of the back plate 904 face one another. A fastener (e.g., a bolt) may beplaced through the center hole 910 of the front plate 902, through ahole in the vertical bar 812 of the frame 800, and through the centerhole 920 of the back plate 904. This secures the front plate 902 andback plate 904 to the frame 800 with the mounting pins 914 extendingaway from the frame.

Using the housing 300 of FIG. 3A as an example, a panel is aligned onthe frame 800 by inserting the appropriate mounting pin 914 into one ofthe holes in the back of the housing 300 provided by an extension310/312. It is understood that this occurs at each corner of the panel,so that the panel will be aligned with the frame 800 using four mountingpins 914 that correspond to four different coupling mechanisms 900. Itis noted that the pins 914 illustrated in FIG. 9C are horizontallyaligned with the holes 912, while the extensions illustrated in FIG. 3Aare vertically aligned. As described previously, these are alternateembodiments and it is understood that the holes 912/pins 914 andextensions 310/312 should have a matching orientation and spacing.

Once in position, a fastener is inserted through the hole 922 of theback plate 904, through the corresponding hole 912 of the front plate902, and into a threaded hole provided by an extension 310/312 in thepanel 300. This secures the panel to the frame 800. It is understoodthat this occurs at each corner of the panel, so that the panel will besecured to the frame 800 using four different coupling mechanisms 900.Accordingly, to attach or remove a panel, only four fasteners need bemanipulated. The coupling mechanism 900 can remain in place to supportup to three other panels.

In other embodiments, the front plate 902 is not needed. For example, indisplays that are lighter in weight the back of the panel can abutdirectly with the beam. In other embodiments, the center hole 920 andcorresponding bolt are not necessary. In other words the entireconnection is made by the screws through the plate 904 into the panel.

The embodiment illustrated here shows a connection from the back of thedisplay. In certain applications, access to the back of the panels isnot available. For example, the display may be mounted directly on abuilding without a catwalk or other access. In this case, the holes inthe panel can extend all the way through the panel with the bolts beingapplied through the panel and secured on the back. This is the oppositedirection of what is shown in FIG. 9C.

More precise alignment may be provided by using an alignment plate, suchas the alignment plate 314 of FIG. 3B, with each panel. For example,while positioning the panel and prior to tightening the couplingmechanism 900, the tabs 316 of the alignment plate 314 for that panelmay be inserted into slots 318 in surrounding alignment plates. Thecoupling mechanism 900 may then be tightened to secure the panel intoplace.

It is understood that many different configurations may be used for thecoupling mechanism 400. For example, the locations of holes and/or pinsmay be moved, more or fewer holes and/or pins may be provided, and othermodifications may be made. It is further understood that many differentcoupling mechanisms may be used to attach an panel to the frame 106.Such coupling mechanisms may use bolts, screws, latches, clips, and/orany other fastener suitable for removably attaching a panel to the frame800.

FIG. 10A illustrates power connections, FIG. 10B illustrates dataconnections, FIG. 10C illustrates power connections, and FIG. 10Dillustrates data connections.

Referring to FIGS. 10A and 10B, one embodiment of a 13×22 panel display1000 is illustrated that includes two hundred and eighty-six panelsarranged in thirteen rows and twenty-two columns. For purposes ofexample, the display 1000 uses the previously described main panel 400of FIG. 4A (a ‘B’ panel) and the slave panel 600 of FIG. 6A (a ‘C’panel). As described previously, these panels have a bi-directionalinput/output connection point for data communications between the mainpanel and the slave panels. The rows are divided into two sections withthe top section having seven rows and the bottom section having sixrows. The B panels form the fourth row of each section and the remainingrows are C panels. FIGS. 10C and 10D provide enlarged views of a portionof FIGS. 10A and 10B, respectively.

As illustrated in FIG. 10A, power (e.g., 220V single phase) is providedto the top section via seven breakers (e.g., twenty amp breakers), witha breaker assigned to each of the seven rows. Power is provided to thebottom section via six breakers, with a breaker assigned to each of thesix rows. In the present example, the power is provided in a serialmanner along a row, with power provided to the first column panel viathe power source, to the second column panel via the first panel, to thethird column panel via the second panel, and so on for the entire row.Accordingly, if a panel is removed or the power for a panel isunplugged, the remainder of the panels in the row will lose power.

As illustrated in FIG. 10B, data is sent from a data source 1002 (e.g.,a computer) to the top section via one line and to the bottom sectionvia another line. In some embodiments, as illustrated, the data linesmay be connected to provide a loop. In the present example, the data isprovided to the B panels that form the fourth row of each section. The Bpanels in the fourth row feed the data both vertically along the columnand in a serial manner along the row. For example, the B panel at rowfour, column two (r4:c2), sends data to the C panels in rows one, two,three, five, six, and seven of column two (r1-3:c2 and r5-7:c2), as wellas to the B panel at row four, column three (r4:c3). Accordingly, if a Bpanel in row four is removed or the data cables are unplugged, theremainder of the panels in the column fed by that panel will lose theirdata connection. The next columns will also lose their data connectionsunless the loop allows data to reach them in the opposite direction.

It is understood that the data lines may be bi-directional. In someembodiments, an input line and an output line may be provided, ratherthan a single bi-directional line as illustrated in FIGS. 10A and 10B.In such embodiments, the panels may be configured with additional inputand/or output connections. An example of this is provided below in FIGS.11A and 11B.

Referring to FIGS. 11A and 11B, one embodiment of a 16×18 panel display1100 is illustrated that includes two hundred and eighty-eight panelsarranged in sixteen rows and eighteen columns. Each power line connectsto a single 110 v 20 amp breaker. All external power cables are 14 AWGSOW UL while internal power cables must be 14 AWG UL. For purposes ofexample, the display 1100 uses the previously described main panel 500of FIG. 5 (a ‘B’ panel) and the slave panel 700 of FIG. 7 (a ‘C’ panel).As described previously, these panels have separate input and outpointconnection points for data communications between the main panel and theslave panels. FIGS. 11C and 11D provide enlarged views of a portion ofFIGS. 11A and 11B, respectively.

As illustrated in FIG. 11A, power is provided from a power sourcedirectly to the first column panel and the tenth column panel of eachrow via a power line connected to a single 110V, 20 A breaker. Thosepanels then feed the power along the rows in a serial manner. Forexample, the power is provided to the first column panel via the powersource, to the second column panel via the first panel, to the thirdcolumn panel via the second panel, and so on until the ninth columnpanel is reached for that row. The ninth column panel does not feedpower to another panel because power is provided directly to the tenthcolumn panel via the power source. Power is then provided to theeleventh column panel via the tenth panel, to the twelfth column panelvia the eleventh panel, and so on until the end of the row is reached.Accordingly, if a panel is removed or the power for a panel isunplugged, the remainder of the panels in the row that rely on thatpanel for power will lose power.

Although not shown in FIG. 11B, the panels of the display 1100 may bedivided into two sections for data purposes as illustrated previouslywith respect to FIG. 10B. Accordingly, as illustrated in FIG. 10B, datamay be sent from a data source (e.g., a computer) to a top section viaone line and to a bottom section via another line. As the presentexample illustrates the use of separate input and outpoint connectionpoints for data communications between the main panel and the slavepanels, data connections between B panels have been omitted for purposesof clarity.

In the present example, the data is provided to the B panels that formthe fourth row of each section. The B panels in the fourth row feed thedata both vertically along the column and in a serial manner along therow (as shown in FIG. 10B). For example, the B panel at row four, columntwo (r4:c2), sends data to the C panels in rows one, two, three, five,six, seven, and eight of column two (r1-3:c2 and r5-8:c2), as well as tothe B panel at row four, column three (r4:c3). Accordingly, if a B panelin row four is removed or the data cables are unplugged, the remainderof the panels in the column fed by that panel will lose their dataconnection. The next columns will also lose their data connectionsunless the loop allows data to reach them in the opposite direction.

Referring to FIGS. 12A and 12B, one embodiment of a 19×10 panel two facedisplay 1100 is illustrated that includes three hundred and eightypanels arranged in two displays of nineteen rows and ten columns. Eachface requires 19 110 V 20 AMP circuit breakers. For purposes of example,the display 1100 uses the previously described main panel 500 of FIG. 5(a ‘B’ panel) and the slave panel 700 of FIG. 7 (a ‘C’ panel). Asdescribed previously, these panels have separate input and outpointconnection points for data communications between the main panel and theslave panels. FIGS. 12C and 12D provide enlarged views of a portion ofFIGS. 12A and 12B, respectively.

As illustrated in FIG. 12A, power is provided from a power sourcedirectly to the first column panel of each face via a power lineconnected to a single 110V, 20 A breaker. Those panels then feed thepower along the rows in a serial manner. For example, the power isprovided to the first column panel of the first face via the powersource, to the second column panel via the first panel, to the thirdcolumn panel via the second panel, and so on until the last panel isreached for that row of that face. The tenth column panel does not feedpower to the next face because power is provided directly to the firstcolumn of the second face via the power source. Power is then providedto the second column panel via the first panel, to the third columnpanel via the second panel, and so on until the last panel is reachedfor that row of that face. Accordingly, if a panel is removed or thepower for a panel is unplugged, the remainder of the panels in the rowthat rely on that panel for power will lose power.

Although not shown in FIG. 12B, the panels of the display 1200 may bedivided into three sections for data purposes as illustrated previouslywith respect to FIG. 10B. Accordingly, as illustrated in FIG. 10B, datamay be sent from a data source (e.g., a computer) to the top section viaone line, to a middle section via a second line, and to a bottom sectionvia a third line. Each master control cabinet has six data cables and isconfigured to be in row 4. Two rows of cabinets use only 5 cables whilethe sixth cable is unused and tied back.

As the present example illustrates the use of separate input andoutpoint connection points for data communications between the mainpanel and the slave panels, data connections between B panels have beenomitted for purposes of clarity. However, a separate line may be run tothe B panels in the first column of each face (which would require sixlines in FIG. 12B), or the B panel in the last column of a row of oneface may pass data to the B panel in the first column of a row of thenext face (which would require three lines in FIG. 12B).

In the present example, the data is provided to the B panels that formthe fourth row of each section. The B panels in the fourth row feed thedata both vertically along the column and in a serial manner along therow (as shown in FIG. 10B). For example, the B panel at row four, columntwo (r4:c2), sends data to the C panels in rows one, two, three, five,and six of column two (r1-3:c2 and r5-6:c2), as well as to the B panelat row four, column three (r4:c3). Accordingly, if a B panel in row fouris removed or the data cables are unplugged, the remainder of the panelsin the column fed by that panel will lose their data connection. Thenext columns will also lose their data connections unless the loopallows data to reach them in the opposite direction.

FIG. 13 illustrates a modular display panel in accordance withembodiments of the present invention. FIG. 14 illustrates a modulardisplay panel attached to a supporting frame in accordance with anembodiment of the present invention. FIG. 15 illustrates a frame used toprovide mechanical support to the modular display panel in accordancewith an embodiment of the present invention.

The multi-panel modular display panel 1300 comprises a plurality of LEDdisplay panels 1350. In various embodiments describe herein, the lightemitting diode (LED) display panels 1350 are attached to a frame 1310 orskeletal structure that provides the framework for supporting the LEDdisplay panels 1350. The LED display panels 1350 are stacked next toeach other and securely attached to the frame 1310 using attachmentplate 1450, which may be a corner plate in one embodiment. Theattachment plate 1450 may comprise holes through which attachmentfeatures 1490 may be screwed in, for example.

Referring to FIGS. 13 and 14, the LED display panels 1350 are arrangedin an array of rows and columns. Each LED display panel 1350 of each rowis electrically connected to an adjacent LED display panel 1350 withinthat row.

Referring to FIG. 15, the frame 1310 provides mechanical support andelectrical connectivity to each of the LED display panels 1350. Theframe 1310 comprises a plurality of beams 1320 forming the mechanicalstructure. The frame 1310 comprises a top bar, a bottom bar, a left bar,a right bar, and a plurality of vertical bars extending from the top barto the bottom bar, the vertical bars disposed between the left bar andthe right bar. The top bar, the bottom bar, the left bar and the rightbar comprise four inch aluminum bars and wherein the vertical barscomprise 2″×4″×½″ aluminum tubes. The top bar, the bottom bar, the leftbar and the right bar are each capable of bearing a load of 1.738 lb/ftand wherein the vertical bars are each capable of bearing a load of 3.23lb/ft.

The frame 1310 may include support structures for the electrical cables,data cables, electrical power box powering the LED displays panels 1350,and data receiver box controlling power, data, and communication to theLED displays panels 1350.

However, the frame 1310 does not include any additional enclosures toprotect the LED panels, data, and power cables from the environment.Rather, the frame 1310 is exposed to the elements and further exposesthe LED display panels 1350 to the environment. The frame 1310 also doesnot include air conditioning, fans, or heating units to maintain thetemperature of the LED display panels 1350. Rather, the LED displaypanels 1350 are hermetically sealed themselves and are designed to beexposed to the outside ambient. Further, in various embodiments, thereare not additional cabinets that are attached to the frame 1310 or usedfor housing the LED display panels 1350. Accordingly, in variousembodiments, the multi-panel modular display panel 1300 is designed tobe only passively cooled.

FIGS. 25A-25D illustrate specific examples of an assembled displaysystem 1300 and FIG. 26 illustrates a specific example of a frame 1310.As shown in FIG. 25A, the modular display system 1300 includes a numberof LED display panels 1350 mounted to frame 1310. One of the displaypanels has been removed in the lower corner to illustrate the modularnature of the display. In this particular example, access is provided tothe back of the modular display through a cage 1390 that includes anenclosed catwalk. Since the display system 1300 is generally highlyelevated, a ladder (see FIG. 25C) provides access to the catwalk. A sideview of the display system is shown in FIG. 25B and back views are shownin FIGS. 25C and 25D.

FIG. 26 illustrates the frame 1310 without the display panels 1350. Inthis embodiment the beams 1320 that form that outer frame are biggerthan the interior beams 1325. In this case, the interior beams 1325 arealigned in a plane outside those of the frame beams 1322. The plates1315 are also shown in the figure. Upon installation, these plates willbe rotated by 90 degrees and fasten to the display panels.

FIG. 16, which includes FIGS. 16A-16C, illustrates an attachment plateused to attach one or more modular display panels to the frame inaccordance with an embodiment of the present invention. FIG. 16Aillustrates a projection view while FIG. 16B illustrates a top view andFIG. 16C illustrates a cross-sectional view.

Referring to FIGS. 16A-16C, the attachment plate 1450 may comprise oneor more through openings 1460 for enabling attachment features such asscrews to go through. Referring to FIG. 16C, the attachment plate 1450comprises a top surface 1451 and a bottom surface 1452. The height ofthe pillars 1480 may be adjusted to provide a good fit for the displaypanel. Advantageously, because the frame 1310 is not screw mounted tothe display panel 1350, the display panel 1350 may be moved duringmounting. This allows for improved alignment of the display panelsresulting in improved picture output. An alignment plate could also beused as described above.

Accordingly, in various embodiments, the height of the pillars 1480 isabout the same as the beams 1320 of the frame 1310. In one or moreembodiments, the height of the pillars 1480 is slightly more than thethickness of the beams 1320 of the frame 1310.

FIGS. 16D and 16E illustrate another embodiment of the attachment plate1450. In this example, the plate is rectangular shaped and not a square.For example, the length can be two to four times longer than the width.In one example, the length is about 9 inches while the width is about 3inches. The holes in the center of the plate are optional. Conversely,these types of holes could be added to the embodiment of FIGS. 16A and16B. In other embodiments, other shaped plates 1450 can be used.

FIG. 17 illustrates a magnified view of the attachment plate or aconnecting plate, frame, and display panel after mounting in accordancewith embodiments of the present invention.

Referring to FIG. 17, one or more attachment features 1490 may be usedto connect the attachment plate 1450 to the display panel 1350. In theembodiment illustrated in FIG. 17, the attachment plate 1450 is a cornerplate. Each corner plate is mechanically connected to corners of four ofthe LED display panels 1350 to secure the LED display panels 1350 to therespective beams 1320 of the frame 1310.

FIG. 17 illustrates that the attachment features 1490 is attached usingthe through openings 1460 in the attachment plate 1450. The frame isbetween the attachment plate 1450 and the display panel 1350.

In the embodiment of FIG. 17, the beam 1320 physically contacts thedisplay panel 1350. In another embodiment, a second plate (not shownhere) could be included between the beam 1320 and the display panel1350. The plate could be a solid material such as a metal plate or couldbe a conforming material such as a rubber material embedded with metalparticles. In either case, it is desirable that the plate be thermallyconductive.

FIG. 18 illustrates one unit of the modular display panel in accordancewith an embodiment of the present invention.

FIG. 18 illustrates one of the multi-panel modular display panel 1300comprising an input cable 1360 and an output cable 1365. The LED displaypanels 1350 are electrically connected together for data and for powerusing the input cable 1360 and the output cable 1365.

Each modular LED display panel 1350 is capable of receiving input usingan integrated data and power cable from a preceding modular LED displaypanel and providing an output using another integrated data and powercable to a succeeding modular LED display panel. Each cable ends with anendpoint device or connector, which is a socket or alternatively a plug.

Referring to FIG. 18, in accordance with an embodiment, a LED displaypanel 1350 comprises an attached input cable 1360 and an output cable1365, a first connector 1370, a second connector 1375, a sealing cover1380. The sealing cover 1380 is configured to go over the secondconnector 1375 thereby hermetically sealing both ends (first connector1370 and the second connector 1375). The sealing cover 1380, which alsoincludes a locking feature, locks the two cables together securely. Aswill be described further, the input cable 1360 and the output cable1365 comprise integrated data and power wires with appropriateinsulation separating them.

FIG. 19 illustrates two display panels next to each other and connectedthrough the cables such that the output cable 1365 of the left displaypanel 1350 is connected with the input cable 1360 of the next displaypanel 1350. The sealing cover 1380 locks the two cables together asdescribed above.

FIG. 20 illustrates a modular multi-panel display system comprising aplurality of LED display panels connected together using theafore-mentioned cables.

Referring to FIG. 20, for each row, a LED display panel 1350 at a firstend receives an input data connection from a data source and has anoutput data connection to a next LED display panel in the row. Eachfurther LED display panel 1350 provides data to a next adjacent LEDdisplay panel until a LED display panel 1350 at second end of the row isreached. The power line is run across each row to power the LED displaypanels 1350 in that row.

In one embodiment, the plurality of LED display panels 1350 includes 320LED display panels 1350 arranged in ten rows and thirty-two columns sothat the integrated display panel 1300 has a display surface that isapproximately fifty feet and four inches wide and fifteen feet and eightand three-quarters inches high.

In various embodiments, as illustrated in FIGS. 14 and 20, a datareceiver box 1400 is mounted to the mechanical support structure orframe 1310. The data receiver box 1400 is configured to provide power,data, and communication to the LED display panels 1350. With a sharedreceiver box 1400, the panels themselves do not need their own receivercard. This configuration saves cost and weight.

FIG. 21, which includes FIGS. 21A-21C, illustrates an alternativeembodiment of the modular display panel attached to a supporting framein accordance with an embodiment of the present invention. FIGS. 21B and21C illustrate alternative structural embodiments of the supportingframe.

This embodiment differs from embodiment described in FIG. 14 in that thehorizontal beams 1320A may be used to support the display panels 1350.In one embodiment, both horizontal beams 1320A and vertical beams 1320Bmay be used to support the display panels 1350. In another embodiment,horizontal beams 1320A but not the vertical beams 1320B may be used tosupport the display panels 1350.

FIG. 21B illustrates an alternative embodiment including additionalbeams 1320C, which may be narrower than the other beams of the frame.One or more of the thinner beams 1320C may be placed between the regularsized vertical beams 1320B.

FIG. 21C illustrates a further embodiment illustrating both a top view,bottom view and side view of a frame. The frame 1310 may be attached toa wall or other structure using plates 1315. The frame 1310 may comprisea plurality of vertical beams and horizontal beams. In one embodiment,the frame 1310 comprises an outer frame having a top bar, a bottom bar,a left bar and a right bar. A display panel 1350 may be supportedbetween two adjacent beams 1320 marked as L3 beams, which may be thinner(smaller diameter) and lighter than the thicker and heavier load bearingbeams 1321 marked as L2 beams used for forming the outer frame. As anillustration, the L2 beams may be 4″ while the L3 beams may be 3″ in oneexample.

FIG. 22 illustrates a method of assembling a modular multi-panel displaysystem in accordance with an embodiment of the present invention. FIG.22 illustrates a method of assembling the multi-panel display systemdiscussed in various embodiments, for example, FIG. 14.

A mechanical support structure such as the frame 1310 described above isassembled taking into account various parameters such as the size andweight of the multi-panel display, location and zoning requirements, andothers (box 1501). For example, as previously described, the mechanicalsupport structure includes a plurality of vertical bars and horizontalbars. The mechanical support structure may be fabricated from acorrosion resistant material in one or more embodiments. For example,the mechanical support structure may be coated with a weather-proofingcoating that prevents the underlying substrate from corroding.

A plurality of LED display panels are mounted on to the mechanicalsupport structure so as to form an integrated display panel thatincludes an array of rows and columns of LED display panels as describedin various embodiments (box 1503). Each of the LED display panels ishermetically sealed. Mounting the LED display panels may comprisemounting each LED display panel a respective vertical beam using anattachment plate.

Each of the LED display panels is electrically connected to a datasource and to a power source (box 1505). For example, a first LEDdisplay panel in each row is electrically coupled to the display source.The other LED display panels in each row may be daisy-chain coupled toan adjacent LED display panel (e.g., as illustrated in FIG. 20).

Since the assembled display structure is light weight, significantassembly advantages can be achieved. For example, the panels can beassembled within a warehouse that is remote from the final locationwhere the display will be utilized. In other words, the panels can beassembled at a first location, shipped to second location and finalizedat the second location.

An illustration of two assembled displays that are ready for shipment isprovided in FIG. 23. These displays can be quite large, for example muchlarger than a 14×48 panel display. In some cases, a single displaysystem is shipped as a series of sub-assemblies, e.g., as shown in thefigure, and then assembled into a full display on location.

In various embodiments, the assembled multi-panel display systemincludes no cabinets. The assembled multi-panel display system is cooledpassively and includes no air conditioning or fans.

Although the preferred embodiment has been described in detail, itshould be understood that various changes, substitutions and alterationscan be made therein without departing from the spirit and scope of theinvention as defined by the appended claims

What is claimed is:
 1. A method of assembling a modular multi-paneldisplay system, the method comprising: receiving from a first location aplurality of integrated display panel sub-assemblies comprising aplurality of display panels detachably mounted to a mechanical supportstructure, each sub-assembly including a plurality of display panelsarranged in an array, wherein each display panel comprises a waterproofouter front surface and includes: a shell comprising a hollow regiontherein; an array of light emitting diodes comprising a plurality ofrows of light emitting diodes and a plurality of columns of lightemitting diodes so as to form a display panel surface; circuitry coupledto the array of light emitting diodes and disposed within the hollowregion of the shell; and a power converter electrically coupled to thecircuitry, wherein the power converter is configured to receive analternating current (AC) at an input and to output a direct current(DC); and at a second location remote from the first location, buildingthe modular multi-panel display system by assembling the sub-assembliesinto an integrated display panel.
 2. The method of claim 1, wherein themechanical support structure provides mechanical support to theplurality of display panels without providing waterproof sealing.
 3. Themethod of claim 1, wherein the integrated display panel is mounted to awall.
 4. The method of claim 1, wherein the integrated display panel ismounted to a preexisting billboard.
 5. The method of claim 1, whereinthe array of light emitting diodes are attached to a printed circuitboard, and wherein the printed circuit board is disposed outside thehollow region of the shell.
 6. The method of claim 1, wherein the powerconverter is disposed within the hollow region of the shell.
 7. Themethod of claim 1, wherein the power converter is disposed outside thehollow region of the shell.
 8. The method of claim 1, further comprisingreplacing a defective one of the plurality of display panels afterbuilding the modular multi-panel display system.
 9. A method ofassembling a modular multi-panel display system, the method comprising:receiving from a first location a plurality of integrated display panelsub-assemblies comprising a plurality of display panels detachablymounted to a mechanical support structure, each sub-assembly including aplurality of display panels arranged in an array, wherein each displaypanel comprises a waterproof outer front surface and includes: a shellcomprising a hollow region therein; an array of light emitting diodescomprising a plurality of rows of light emitting diodes and a pluralityof columns of light emitting diodes so as to form a display panelsurface; and circuitry coupled to the array of light emitting diodes anddisposed within the hollow region of the shell, wherein eachsub-assembly comprises a power converter electrically coupled to thecircuitry of one of the respective plurality of display panels, whereinthe power converter is configured to receive an alternating current (AC)at an input and to output a direct current (DC); and at a secondlocation remote from the first location, building a multi-panel displaysystem by assembling the sub-assemblies into an integrated displaypanel.
 10. The method of claim 9, further comprising mounting a datareceiver box adjacent to the plurality of display panels of eachsub-assembly to provide power, data, and communication to each of thepluralities of display panels, wherein the power and the data aresupplied from the data receiver box through separate wires within anintegrated cable.
 11. The method of claim 10, wherein the data receiverbox provides direct current (DC) power to each of the display panels andwherein a power supply unit of each display panel is configured toconvert the DC power to DC power at a different voltage level.
 12. Themethod of claim 9, wherein each of the plurality of display panels aremounted to respective mechanical support structures with attachmentplates.
 13. The method of claim 12, wherein the attachment platescomprise corner plates and wherein each display panel within an interiorportion of the plurality of display panels is attached to two respectivevertical beams by four of the corner plates, each corner plate beingmechanically connected to corners of four of the display panels tosecure the display panels to the respective vertical beam.
 14. Themethod of claim 9, wherein the mechanical support structure providesmechanical support to the plurality of display panels without providingwaterproof sealing.
 15. The method of claim 9, wherein the integrateddisplay panel is mounted to a wall.
 16. The method of claim 9, whereinthe integrated display panel is mounted to a preexisting billboard. 17.The method of claim 9, wherein the array of light emitting diodes areattached to a printed circuit board, and wherein the printed circuitboard is disposed outside the hollow region of the shell.
 18. The methodof claim 9, wherein the power converter is disposed within the hollowregion of the shell.
 19. The method of claim 9, wherein the powerconverter is disposed outside the hollow region of the shell.
 20. Themethod of claim 9, further comprising replacing a defective one of theplurality of display panels after building the modular multi-paneldisplay system.